101607-6871 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016076871


 

Information injection-pump assembly

ZEXEL 101607-6871 1016076871
101607-6871 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 101607-6871 1016076871


Zexel num
Bosch num
Firm num
Name
101607-6871 
 
   
INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8140
Bosch type code   EF8511/9A
Nozzle   105780-0000
Bosch type code   DN12SD12T
Nozzle holder   105780-2080
Bosch type code   EF8511/9
Opening pressure MPa   17.2
Opening pressure kgf/cm2   175
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   6-2-600
Overflow valve   131424-8420
Overflow valve opening pressure kPa   255 221 289
Overflow valve opening pressure kgf/cm2   2.6 2.25 2.95
Tester oil delivery pressure kPa   157 157 157
Tester oil delivery pressure kgf/cm2   1.6 1.6 1.6
Direction of rotation (viewed from drive side)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.2 3.15 3.25
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cal 1-5
deg.   60 59.5 60.5
Difference between angles 2
Cal 1-3
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cyl.1-2
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-4
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   -
Rack position   11.9
Pump speed r/min   850 850 850
Each cylinder's injection qty mm3/st.   86.5 83.9 89.1
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   9.5+-0.5
Pump speed r/min   600 600 600
Each cylinder's injection qty mm3/st.   10.8 9.2 12.4
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.9)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   86.5 85.5 87.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.25
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   88 84 92
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.4
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   71.5 67.5 75.5
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   95 85 105
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   950--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   900
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   -
Advance angle deg.   1 0.5 1.5
Remarks
Measure the actual speed.
 
Timer adjustment_04
Pump speed r/min   1100
Advance angle deg.   1 0.5 1.5
Timer adjustment_05
Pump speed r/min   1400
Advance angle deg.   7 6.5 7.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101607-6871
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=J70
----------

Speed control lever angle

Test data 101607-6871
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=10deg+-5deg b=(47.5deg)+-3deg

Stop lever angle

Test data 101607-6871
N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position). (3)Rack position = approximately ee. (4)Free (at delivery)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg

0000001201

Test data 101607-6871
F:At operation, hold it in the full speed position. I:Idle (1)At rack position aa and pump speed bb, set the stopper bolt. (After setting it, apply red paint.) (2)Actual measurement
----------
aa=9.9+-0.1mm bb=1575r/min
----------
a=15deg+-5deg

Timing setting

Test data 101607-6871
(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=7deg
----------
a=(3deg)




Information:


U.S. EPA regulations require the use of Ultra Low Sulfur Diesel fuel (ULSD) , ≤0.0015 percent (≤15 ppm (mg/kg)) sulfur, for nonroad and stationary Tier 4 EPA certified engines using fuel sensitive technologies such as SCR systems and particulate filters. Fuels other than ULSD can cause damage in those engines and should not be used.Consult the U.S. EPA for fuel sulfur regulations and for the ULSD point of sales required dates for various nonroad applications.European sulfur free fuel ≤0.0010 percent (≤10ppm (mg/kg) sulfur) fuel is required by regulation for use in engines certified to EU nonroad Stage IIIB and newer standards and that are equipped with exhaust aftertreatment systems.Certain governments/localities and/or applications MAY require the use of ULSD fuel. Consult federal, state, and local authorities for guidance on fuel requirements for your area.Typical aftertreatment systems include Diesel Particulate Filters (DPF), Diesel Oxidation Catalysts (DOC), Selective Catalytic Reduction (SCR) and/or Lean NOx Traps (LNT). Other systems may apply.Low sulfur diesel (LSD) fuel (≤500 ppm (mg/kg) sulfur) is strongly recommended for use in engines that are pre-Tier 4 models while diesel fuel with >500 ppm sulfur is acceptable for use in areas of the world where allowed by law. Pre-Tier 4 engines that are equipped with a Diesel Oxidation Catalyst (DOC) require the use of LSD fuel or ULSD fuel.ULSD fuel or sulfur-free diesel fuel are acceptable in all engines regardless of the engine U.S. EPA Tier or EU Stage requirements.Use appropriate lubricating oils that are compatible with the engine certification and aftertreatment system and with the fuel sulfur levels. Refer to the “Diesel Fuel Sulfur Impacts” article of this “Fuels Specifications” section and to the “Lubricants Specifications” section of this Special Publication.
The two basic types of distillate diesel fuel are No. 2 diesel fuel and No. 1 diesel fuel. No. 2 diesel fuel is the most commonly available summer grade diesel fuel. No. 1 diesel fuel is a winter grade diesel fuel. During the winter months fuel suppliers will typically blend No. 1 and No. 2 diesel fuel in various percentages. Blending allows the fuel to meet the historical low ambient temperature cold-flow needs for a given area or region. No. 2 diesel fuel is a heavier diesel fuel than No. 1 diesel fuel. In cold weather, heavier fuels can cause problems with fuel filters, fuel lines, fuel tanks, and fuel storage. Heavier diesel fuels such as No. 2 diesel fuel can be used in diesel engines that operate in cold temperatures with an appropriate amount of a proven pour point depressant additive. For more information on fuels which include blends of No. 1 and No. 2 diesel fuel, consult your fuel supplier.When you use No. 2 diesel fuel or other heavier fuels, some of the fuel characteristics may interfere with successful cold-weather operation. Additional information about the characteristics of diesel fuel is available. This information contains a discussion on the modification to the characteristics of diesel fuel. There are several possible methods that can be used to compensate

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